Prefabricated structural unit body and structures thereof

ABSTRACT

This invention relates generally to building construction and more particularly to a prefabricated structural unit body offering protection against fire, which is heat and soundinsulating, which has elastic properties and which is durable, and to a structural body built up by connecting such structural unit bodies. The structural unit body comprises a first frame body and a second smaller frame body forming a stepped frame body and joined to an assembly unit which includes a felt-like material a dampproof material, and a net-like material. The prefabricated unit body is used for building walls, partition walls, floors, ceilings, and the like.

llnited States Patent [1 1 Megumi 1 Mar. 25, 1975 [75] Inventor: Naomitsu Megumi, Funabashi,

Japan [73] Assignee: Tokyo Plywood Kabushiki Kaisha,

Tokyo, Japan [22] Filed: Oct. 24, 1973 [21] Appl. No.: 409,090

[30] Foreign Application Priority Data 2,363,233 11/1944 Dalton 52/586 2,861,525 11/1958 Curtis et a1. 52/515 X 2,875,478 3/1959 Andre 52/586 3,300,919 l/l967 Hiller 52/586 3,405,592 10/1968 Blodee 52/585 X 3,753,843 8/1973 Hutchison 52/615 X Primary E.\'aminerPrice C. Faw, Jr. Attorney, Agent, or Finn-Frank J. Jordan [57] ABSTRACT This invention relates generally to building construc* tion and more particularly to a prefabricated structural unit body offering protection against fire, which is heat and sound-insulating, which has elastic properties and which is durable, and to a structural body built up by connecting such structural unit bodies. The structural unit body comprises a first frame body and a second smaller frame body forming a stepped frame body and joined to an assembly unit which includes a felt-like material a dampproof material, and a net-like material. The prefabricated unit body is used for building walls, partition walls, floors, ceilings, andthe like.

12 Claims, 12 Drawing Figures PREFABRICATED STRUCTURAL UNIT BODY AND STRUCTURES THEREOF BACKGROUND OF THE INVENTION A structural unit body comprises a rectangular frame body on which there is fixed a smaller similar frame body to thereby form a stepped frame body having a common opening. There is disposed successively over a planer body which is slightly larger than the smaller frame body a felt-like body, a dampproof body, and a metal net body and these are fastened together to form an assembly unit, the arrangement being such that a groove is formed between the stepped frame body and the assembly unit.

SUMMARY OF THE INVENTION A structural unit body includes a stepped frame body and an assembly unit. The assembly unit includes a planar base material, a felt-like material disposed over said planar base material, a dampproof material disposed over said felt-like material, a metallic net-like material disposed over said dampproof material, and fasteners fastening said materials together to definesaid assembly unit. The assembly unit is joined to the stepped frame body to form a structural unit body used in constructing buildings and the like.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a stepped frame body according to one embodiment of the present invention;

FIG. 2 is a perspective view of a stepped frame body according to another embodiment of the invention;

FIG. 3 is a cross-sectional view of a structural unit body;

FIG. 4 is a perspective view partly cutaway of a structural unit body;

FIG. 5 is another perspective view of the structural unit body shown in FIG. 4;

FIG. 6 is a perspective view partly cutaway ofa structural unit body in which mortar is applied to the metallic net body;

FIGS. 7a, 7b and 7c are cross-sectional views respectively of an outer wall construction, an inner wall construction and a floor construction utilizing the structural unit bodies of the present invention;

FIG. 8 is a partial perspective view, partly broken away, of a wall construction utilizing the structural unit bodies of the present invention;

FIG. 9 is a perspective view, partly broken away, of a connection plate utilized in the wall construction shown in FIGS. 7a, 7b, and 7c;

FIG. 10 is a perspective view of an insertion plate utilized in the wall construction shown in FIGS. 7a, 7b and 70.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to a prefabricated structural unit body which protects against fire which is heat and sound insulating, which has elastic properties, and which is durable, and to a structure built up by connecting such structural unit bodies.

Embodiments of the present invention will hereinafter be set forth with reference to the annexed drawings. As shown in FIGS. 1 and 2, a rectangular frame body 1 is provided on which there is fixed a slightly smaller but similar frame body 2 to form a stepped frame body 3 having a step 17 formed with the frame body 2. The stepped frame body 3 is open on the inside and forms an opening portion 16 which is provided with a rail 15 for reinforcement as required. Alternatively it is also possibly to practice the present invention, as shown in FIG. 2, by integrating a frame body 1 and a smaller frame body 2 having an opening portion inside together utilizing such materials as metal, wood, plastic, lightweight concrete, and inorganic board, to thereby form an incorporated block with the latter being used, as a stepped frame body 18 having a step 17 formed with the smaller frame body 2. As shown in FIG. 3, there is disposed over the surface of a rectangular planar body 4 which is slightly larger than the smaller frame body 2 a felt-like or mat-like body 5 made of mineral or inorganic fiber, a dampproof planar body 6, and a metallic net body 7 in succession to form a structural body or assembly unit 9 held together by metallic fasteners 8. This structural body 9 is placed and secured on the small frame body 2 of the stepped frame body 3 (FIG. 1) or on the stepped frame body 18 (FIG. 2) to form a'structural unit body 10 by fixing or securing with nails or glue as shown in FIGS. 4 and 5. Along the circumference of the unit body 10, a circumferential groove 11 is formed which is as wide as the thickness of the smaller frame body 2 or the stepped portion 17. Further, as shown in FIG. 6, material such as mortar 12 may be applied and fixed to the metallic net body 7 of the structural body 9, whereby a finished single block 13 is obtained. In such a case there will be formed a narrow circumferential groove 14.

The stepped body 3 as it relates .to the structure of this invention is so builtup or arranged that a plurality of base plates are assembled in the form of a frame or rail and a rectangular frame body 1 and a smaller similar frame body 2 having the opening 16 are fixed together. The base plate may be a veneer or plywood. Alternatively, as described hereinbefore and as shown in FIG. 2, the frame body 1 and the smaller frame body 2 may be made as an integrated unit with the rail portion 15 formed into an incorporated block to thereby define a stepped frame body 18 having an opening portion 16. The planar body 4 is made of wood, synthetic wood, or the like, and preferably is subjected to treatment with a preservative. As may be required in the construction, the planar body 4 may be provided inside with an opening. The felt-like mineral or inorganic fiber body 5 is formed of fibers such as glass wool, asbestos, slag wool, and rock wool, separately or in mixtures thereof, or mixed with non-combustible synthetic fibers, the arrangement being such that there are voids between fibers. Such a body as the fiber body 5 may take the form of sheet or mat. The fiber body 5 is heatresistant, protects against tire and effectively insulates against sound and heat. For the damp proof planar body 6, materials such as asphalt felt, thick paper, or various kinds of roofing materials are used. The metallic net body 7 is a net-like material in the form of metal lath or wire lath. Metal lath is mostly manufactured by expanding perforated iron sheet and wire lath is mostly a net made of iron wire or chains. The metallic fasteners 8 are forced across the intersection of the metallic net 7 through the dampproof planar body 6, the inorganic fiber felt-like body 5, and the planar body 4 in succession, thereby fastening and tightening all of the material members together. The positions of binding by the fasteners 8 are so chosen that the fastening will be effective physically and functionally, while presenting a good appearance. The thus obtained structural body 9 of the hereinabove described prevents penetration of moisture, and is heat-preserving and heat-insulating. That is, the dampproof planar body 6 interrupts or presents the effect of dampness or moisture from the outer side of the structural body and also from the spaces between or at the back-side of the planar body. The inorganic fiber felt-like body 5 reduces the dampness in the air evolved in or at the side of the dampproof planar body 6 as a result of capillary phenomenon, atomization and vaporization phenomena by the action of the air contained in the fibers. The dampproof planar body 6 and inorganic fiber felt-like body 5 which are fastened as described above by the metallic fasteners 8 become uneven, sinking or rising locally, because of the fastening forces resulting from the metallic fasteners 8 and thereby develop an elasticity. This expanding or contracting effect accelerates vaporization of moisture and, further, provides partition walls to vaporize the dampness uniformly. In the structural body 9, all members are fastened in succession as heretofore described and accordingly, the structural body 9 is elastic and air-permeating and also sound-insulating, and heatinsulating due to the presence of the inorganic fiber felt-like body. In cases where the column and rail are covered with the structural body 9 thus provided, the stability of the frame body and associated bodies is increased. Such bodies are easy to apply and use and, accordingly, are suitable for structural material in the field of building and construction, making possible construction of buildings having good living environmental conditions. Particularly, when finished with mortar, the block is durable since the metallic net serves as a reinforcing member.

The heretofore structural unit body of the present invention is applied as shown in the embodiment in FIGS. 7a, 7b, 7c, and 8. In these figures which are crosssectional views, FIG. 7a shows an example in which an outer wall surface of a column 23 is composed of connected structural unit bodies 10 constructed on the outside with metallic net bodies. FIG. 7b shows an example in which the inner wall surface is composed of structural unit bodies 13 finished on the outside with mortar. The floor face in FIG. 70 is shown in a horizontal disposition. In this drawing, the frame body 1 of the structural unit body 10 or 13 is fixed by nailing as indicated at 32, to a beam 24 mounted horizontally at proper intervals on a column 23 standing vertically on a sill 22 placed on a foundation of concrete 2] on the ground 20. The outer wall surface in FIG. 7a and the inner wall surface in FIG. 7b may be selected for either or both interchangeably and the structural unit body 10 or 13 may be used in combination as desired. The unit body is fixed to the beam 24, and when the succeeding unit body is mounted, it is connected by fitting a connection plate 25 (FIG. 9) into the circumferential groove 14. The connection plate 25 is a narrow and long planar body 30 covered with lath, but alternatively such a connection body may be replaced by a suitable elongated planar body. In this regard it is noted that the connecting plate 25 need only be inserted securely into the circumferential groove 14 and firmly connected therewith. The floor face shown in FIG. 7c likewise need only be assembled in a similar manner. As shown in FIG. 8, the edge portion of each structural unit body adjacent to another structural unit body forms a straight line interval indentation 33 in the construction of each wall surface. Although it may be satisfactory if the construction is effected in such a manner it is preferable to provide a construction in the manner shown in FIGS. 70, 7b and 70, whereby the connection plate 25 shown in FIG. 9 or the insertion plate 26 shown in FIG. 10 is inserted into the interval 33. In the example of an inner wall surface as shown in FIG. 7b, the portion forming the interval 33 may have mortar applied thereto.

The building material of this invention is constructed as described, and the structural unit body is such as to provide for convenience in transportation and handling. The structural unit body is utilized by assembling and connecting into a wall, floor, or ceiling, and the application is easy, with the construction being light in weight and durable. The temperature and humidity inside the house or building is maintained adequately by the felt-like body and the dampproof planar body, and the indoor environment a is accordingly appropriate and very sanitary. The built-up wall, whether it be single or composite, is not likely to warp or crack, and is durable, heat-resisting, and fire-preventing so as to prevent damage by fire. The structural unit body may be used by designing the proper combination and arrangement thereof depending upon the environment and considering the natural lighting and ventialtion through the opening 16, sound insulation, sunshine, and the like in living rooms. As heretofore described, the wall surface, whether it be of metallic net or of mortar face, does not spoil or impair its appearance. The unit price, processing, and transportation are inexpensive and the construction is made economically, thereby making this a feature of this product. Repairs can also be made easily.

I claim:

1. A prefabricated structural unit body having heatresistant, sound-resistant, and moisture barrier properties comprising a first frame body, a second frame body joined to said first frame body, common openings in said first and second frame bodies, said second frame body being smaller than said first frame body and being arranged on the latter to form a step and thereby dfine a stepped frame body, a planar base materiaLa felt-like material disposed on said planar base material, a dampproof planar material disposed over said felt-like material, a metllic net-like material disposed over said dampproof planar material, fasteners extending between said planar base material and said metallic netlike material for fastening said materials together to thereby define an assembly unit, and means joining said assembly unit to said stepped frame body, said assembly unit being larger than said second frame body, whereby there is formed a circumferential groove defined by said step on said stepped frame body and the outer portions of said assembly unit.

2. A structural unit body according to claim 1 wherein said felt-like material is formed of fibers selected from the group consisting of glass wool, asbestos, slag wool, rock wool, and synthetic fibers.

3. A structural unit body according to claim 1 including a layer of mortar on said metallic net-like material.

4. A structural unit body according to claim 1 wherein said stepped frame body is formed as an integral unit.

5. A structural unit body according to claim 1 wherein said first frame body and said second frame body are formed separately, and means joining said first frame body and said second frame body to one another to form said stepped frame body.

6. A structural unit body according to claim 1 wherein said stepped frame body has a rectangular configuration and is provided with two openings separated by a rail element.

7. A building construction comprising a stepped frame body having at leastone through opening and a peripheral step, a planar base material, a felt-like material disposed on said planar base material, a dampproof material disposed over said felt-like material, a metallic net-like material disposed over said dampproof material, fasteners extending between said planar base material and said metallic net-like material for fastening said materials together to thereby define an assembly unit, means joining said assembly unit to said stepped frame body to define a structural unit body having a circumferential groove formed by said step on said stepped frame body and the outer portions of said assembly unit, a plurality of said structural unit bodies being arranged adjacent to one another so that a portion of the circumferential groove of one structural unit body faces a portion of the circumferential groove of another adjacent structural unit body.

8. A building construction according to claim 7 including a connection member disposed within said facing grooves of adjacent structural unit bodies.

9. A building construction according to claim 8 including a beam secured in place on a building, and means securing said connection member to said beam whereby said connection member holds said structural unit bodies in place on said beam.

10. A building construction according to claim 8 including a lath disposed over said connection member.

11. A building construction according to claim 7 wherein a space is provided between the adjacently arranged structural unit bodies.

12. A building construction according to claim 11 including an insertion member disposed in said space.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3,872,640 DATED March 25, 1975 INVENTOR(S) I Naomitsu MEGUMI It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

In the heading of the patent reading "FOREIGN APPLICATIQN PRIORITY DATA" change the filing date from "November 8, 1972 to --November 7, I972--.

Bigncd and Sealed this twenty-ninth D21) Of July 1975 [SEAL] A ttes t:

RUTH C. MASON C. MARSHALL DANN Arresting Officer ('ummissimu'r uj'larcnlx um] Trademarks 

1. A prefabricated structural unit body having heat-resistant, sound-resistant, and moisture barrier properties comprising a first frame body, a second frame body joined to said first frame body, common openings in said first and second frame bodies, said second frame body being smaller than said first frame body and being arranged on the latter to form a step and thereby dfine a stepped frame body, a planar base material, a felt-like material disposed on said planar base material, a dampproof planar material disposed over said felt-like material, a metllic netlike material disposed over said dampproof planar material, fasteners extending between said planar base material and said metallic net-like material for fastening said materials together to thereby define an assembly unit, and means joining said assembly unit to said stepped frame body, said assembly unit being larger than said second frame body, whereby there is formed a circumferential groove defined by said step on said stepped frame body and the outer portions of said assembly unit.
 2. A structural unit body according to claim 1 wherein said felt-like material is formed of fibers selected from the group consisting of glass wool, asbestos, slag wool, rock wool, and synthetic fibers.
 3. A structural unit body according to claim 1 including a layer of mortar on said metallic net-like material.
 4. A structural unit body according to claim 1 wherein said stepped frame body is formed as an integral unit.
 5. A structural unit body according to claim 1 wherein said first frame body and said second frame body are formed separately, and means joining said first frame body and said second frame body to one another to form said stepped frame body.
 6. A structural unit body according to claim 1 wherein said stepped frame body has a rectangular configuration and is provided with two openings separated by a rail element.
 7. A building construction comprising a stepped frame body having at least one through opening and a peripheral step, a planar base material, a felt-like material disposed on said planar base material, a dampproof material disposed over said felt-like material, a metallic net-like material disposed over said dampproof material, fasteners extending between said planar base material and said metallic net-like material for fastening said materials together to thereby define an assembly unit, means joining said assembly unit to said stepped frame body to define a structural unit body having a circumferential groove formed by said step on said stepped frame body and the outer portions of said assembly unit, a plurality of said structural unit bodies being arranged adjacent to one another so that a portion of the circumferential groove of one structural unit body faces a portion of the circumferential groove of another adjacent structural unit body.
 8. A building construction according to claim 7 including a connection member disposed within said facing grooves of adjacent structural unit bodies.
 9. A building construction according to claim 8 including a beam secured in place on a building, and means securing said connection member to said beam whereby said connection member holds said structural unit bodies in place on said beam.
 10. A building construction according to claim 8 including a lath disposed over said connection member.
 11. A building construction according to claim 7 wherein a space is provided between the adjacently arranged structural unit bodies.
 12. A building construction according to claim 11 including an insertion member disposed in said space. 